Single piece light guide having light rod and lens

ABSTRACT

A single piece light guide is disclosed herein. The single piece light guide may include a light rod and a lens. The single piece light guide may be formed using injection molding. The light guide may have one or more regions between the light rod and the lens. A housing may be provided for the light guide. The housing may have an opening that physically supports the light rod. Therefore, the light rod may be secured into place, which may prevent misalignment during use. The one or more regions between the light rod and the lens may assist in assembling and holding the light guide in the housing.

BACKGROUND

Light pipes and guides have a variety of applications. A light guidereceives light from a light source and transports it some distance withminimal loss. For example, light from one or more LEDs can betransmitted to another location. The light guide may also process thelight in some manner. For example, the light guide may integrate lightof different colors. The light guide may also collimate the light. Onepossible application for a light guides is in a light projector.

As with other areas of technology, there are benefits to making lightprojectors and other devices that use light guides smaller. Onepotential application for light projectors may be cellular telephones.Therefore, there may be a need for smaller components for lightprojectors, as well as other optical devices that use light guides.However, there are challenges in economically making light guides thatare small, reliable, and of high quality.

Moreover, there are challenges in assembling a device that uses a lightguide. Considerable time and effort can be taken to properly align thelight guide to the light source and other optical elements, such thatlight may be transmitted efficiently. Moreover, assembly may become morechallenging as devices scale down in size.

Furthermore, during use, devices that use light guides may be subject tobeing dropped or suffer from other jarring events. Such events may causemisalignment of the light guide.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a perspective view of one embodiment of a light guide.

FIG. 2 is a perspective view of one embodiment of the light guide ofFIG. 1.

FIG. 3A, FIG. 3B, FIG. 3C, and FIG. 3D depict side plan views of oneembodiment of the light guide of FIG. 1.

FIG. 4A depicts a top plan view of one embodiment of the light guide ofFIG. 1.

FIG. 4B depicts a bottom plan view of one embodiment of the light guideof FIG. 1.

FIG. 5 depicts one embodiment of a light guide without regions betweenthe light rod and lens.

FIG. 6 depicts one embodiment of light guide optically coupled to an LEDmodule.

FIG. 7A depicts a block diagram of one embodiment of a light engine inwhich embodiments of light guide may be used.

FIG. 7B depicts a block diagram of one embodiment of a light engine thatuses transmissive technology in the panel module.

FIG. 7C depicts further details of one embodiment of a light engine inwhich embodiments of light guide may be used.

FIG. 8A depicts a perspective view of one embodiment of a housing.

FIG. 8B depicts a top plan view of one embodiment of a housing.

FIG. 8C depicts a cross sectional view of one embodiment of a housingand LED module.

FIG. 8D depicts a side plan view of one embodiment of housing with alight guide inside.

FIG. 8E depicts an interior piece of housing surrounding a light guide.

FIG. 8F depicts a perspective view of one embodiment of a two-piecehousing.

FIG. 9A depicts a side plan view of one embodiment of an interior pieceof a housing.

FIG. 9B depicts a cross section of one embodiment at line B-B of FIG.9A.

FIG. 9C depicts a cross section of one embodiment at line C-C of FIG.9A.

FIG. 10 depicts a cross section of one embodiment of housing and lightguide.

FIG. 11 depicts a cross section of one embodiment of housing and lightguide.

FIG. 12 depicts a flowchart of one embodiment of a process ofmanufacturing a single piece light guide.

FIG. 13 depicts a flowchart of one embodiment of a process ofconfiguring a light source housing assembly into a light engine.

FIG. 13A depicts a flowchart of one embodiment of a process ofconfiguring a light source housing assembly.

FIG. 13B depicts a flowchart of one embodiment of a process ofconfiguring a light source housing assembly.

DETAILED DESCRIPTION

Disclosed herein are light guides, light engines that use light guides,methods for making light guides, and methods for assembling light sourcehousing assemblies.

A single piece light guide and methods for making a single piece lightguide are included in embodiments disclosed herein. The single piecelight guide of one embodiment includes a light rod and a lens. In oneembodiment, the light rod integrates light of different colors. In oneembodiment, the lens is a collimating lens. In one embodiment, thesingle piece light guide is formed using injection molding. The singlepiece light guide can be manufactured inexpensively. Moreover, there isno need to align the lens with the light rod. Note that someconventional light guides may require that a lens is physically alignedto a light rod or light guide, which can be quite time consuming andprone to misalignment. Moreover, the lens of embodiments of a singlepiece light guide can be assured to be properly aligned to the lightrod.

One embodiment includes a housing that surrounds a light rod. Together,the housing and light guide (with perhaps other complements) may bereferred to as a light source housing assembly. The housing may providephysical support for the light rod. For example, the housing may have aconical opening that physically supports a tapered light rod. Therefore,the light rod may be secured into place, which may prevent misalignmentduring use. The housing may facilitate proper alignment of the lightguide to a light source, as well as other optical elements. Also, thehousing may facilitate assembly of the light guide into a device (suchas a light engine). Therefore, one embodiment of a light source housingassembly can be quickly, accurately, and economically assembled.

One embodiment includes a light guide that has one or more regionsbetween a light rod and lens. These regions may be used to help alignand/or secure the light guide into a housing. It is possible that anouter surface of the region(s) has physical contact with the housing.Note that for some conventional devices that transmit light usinginternal reflection, light may escape rather than be internallyreflected if an element physically contacts the outside of a device.However, the outer surfaces of embodiments of the region between thelight rod and lens may be located such that physical contact with ahousing does not cause light loss. For example, the outer surfaces ofthe regions may be located away from an optical path, such that littleor no light needs to be internally reflected when passing through theregions.

FIG. 1, FIG. 2, FIGS. 3A-3D, and FIGS. 4A-4B depict one embodiment of alight guide 100. FIGS. 1 and 2 depict perspective views. FIGS. 3A-3Ddepict side plan views. FIG. 4A depicts a top plan view. FIG. 4B depictsa bottom plan view. The following discussion may refer to one or more ofFIGS. 1-4B.

Light guide 100 may include a light rod 102 and a lens 104. Light guide100 of one embodiment also includes regions 106 and 108 between lightrod 102 and lens 104. FIG. 3A depicts dashed lines to depict the extentof the regions 106, 108 for one embodiment. Note that since regions 106and 108 are physically interposed between light right 102 and lens 104in some embodiments, that light may travel through at least a portion ofregions 106 and 108. Regions 106 and 108 will be discussed more fullybelow.

In one embodiment, light rod 102 has a light entrance 110 at a first endthat receives or captures light. The light may be captured from a lightsource, such as one or more LEDs (not depicted in FIGS. 1-4B). As onealternative, laser light might be used. Light entrance 110 is depictedas having a flat surface in FIGS. 1-4B. However, a flat surface is notrequired. Light entrance 110 has a curved surface in one embodiment. Acurved surface may improve the efficiency of capturing light from alight source, depending on the shape of the light source. In someembodiments, a curved surface is used when the light source is a singleLED. The surface of light entrance 110 may have a coating to improveefficiency of light capture. However, the coating is not required.

Light rod 102 has a second end that serves as a light exit 112 (see, forexample, FIG. 2). Thus, light rod 102 is able to capture and transmitlight. By light exit it is meant that light exits light rod 102. Notethat light exit 112 may be joined to another part of light guide 100,such as region 106. Therefore, light does not necessarily leave lightguide 100 at light exit 112. Note that light exit 112 may be at theborder between light rod 102 and region 106. FIG. 1 shows how the secondend of light rod 102 meets the lower surface 116 of region 106.

Light exit 112 may have a rectangular shape. However, light exit 112could have a shape other than rectangular. In some embodiments, theshape of light exit 112 is similar to that of a target region toilluminate. For example, if light guide 100 is being used in a lightengine of a projector with a desired display having a 16:9 aspect ratio,then light exit 112 could have this aspect ratio. However, note thatthis is not a requirement, as other elements can be used to shape lightafter it leaves light guide 100.

Light rod 102 may taper from light exit 112 towards light entrance 110.For example, light rod 102 may get progressively more narrow towardslight entrance 110. Light rod 102 has four sides and four edges betweenlight exit 112 and light entrance 110, in one embodiment. However, lightrod 102 could have more or fewer than four sides. Likewise, light rod102 could have more or fewer than four edges. Also, light rod 102 is notrequired to be tapered.

In some embodiments, the sides of light rod 102 that are essentiallyparallel to the direction of light travel (or optical axis) are smooth.Having smooth sides may improve efficiency of light transfer. Theoutside surface of light rod 102 may optionally be painted, or have someother type of coating, to improve efficiency of light transfer. Thecolor and/or type of coating may be selected to help prevent light fromescaping from the side walls of light rod 102.

In some embodiments, light is transmitted through light rod 102 by totalinternal reflection. In one embodiment, the light reflects about twicein its travel through light rod 102. For example, for a light rod 102that is between 7-8 mm in length, light may reflect twice, given otherparameters, such as the taper and range of light frequencies. However,light rod 102 may be shorter than 7 mm or longer than 8mm.

In one embodiment, light rod 102 is able to mix or integrate light ofdifferent colors. For example, light entrance 110 may capture light fromone or more red, blue, and green LEDs. The light rod 102 may uniformlydisperse light emitted from the LEDs. However, the light source could bea single color of light. Therefore, light exit 112 may output light of asingle color (red light, for example). Thus, it is not required thatlight rod 102 be used to uniformly disperse light of different colors.

Herein, embodiments of light rod 102 may be referred to as an“integrating optic.” It will be understood that this means that lightrod 102 has the ability to integrate light of different colors.

In one embodiment, light entrance 110 may have dimensions of about 1.15mm×1.26 mm. However, light entrance 110 may have larger or smallerdimensions. In one embodiment, light exit 112 has dimensions of about2.16×1.26 mm. Therefore, the diagonal (“d”) of light exit 112 may beabout 2.5 mm.

Lens 104 has a convex shape in one embodiment. However, a convex shapeis not required in all embodiments. The shape of lens 104 may be lessthan a hemisphere in one embodiment. Lens 104 has a radius of about 3mm, in one embodiment. However, the radius (R) could be larger orsmaller. As noted, light exit 112 may have a diagonal (d) of about 2.5mm, in one embodiment. Therefore, R/d may be about 1.2, in oneembodiment. Note that R/d could be greater or smaller. Lens 104 may havea clear aperture of about 5.2 mm. The surface of lens 104 may have ananti-reflecting coating. For example, the reflection may be about 1% orless for light that is normal incident at the lens 104. Note that theanti-reflecting coating is not a requirement.

In one embodiment lens 104 of light guide 100 is a collimating lens.However, in some embodiments, the lens 104 performs a function otherthan collimating the light. For example, lens 104 may be a focusinglens. Thus, lens 104 is not required to collimate light, in allembodiments.

Lens 104 may be optically coupled to the light exit 112 (of light rod102. Note that light from light exit 112 may pass through a portion ofregions 106 and/or 108 before arriving at lens 104. Therefore, it willbe understood that “optically coupled to” may include indirectlyoptically coupled through one or more regions such as 106 and/or 108.

Light guide 100 may be formed from an optical grade material. Examplesof optical grade materials include, but are not limited to, acrylicresins, polycarbonates, epoxies, and glass. In some embodiments, theentire light guide 100 is formed from the same material. However, insome embodiments, light guide 100 is formed from two or more differentmaterials. In one embodiment, light rod 102 is solid. For example, lightrod 102 may be a solid integrating optic. In one embodiment, light rod102 is hollow.

In some embodiments, light guide 100 is manufactured as a single piece.As one example, injection molding can be used to form light guide 100.Note that this means that there is no need to align lens 104 with lightrod 102. Element 107 (see, FIG. 3A, 3B, 4A, 4B) results from oneembodiment of the injection molding process, and is not required. Theinjection molding process may involve closing a mold, and then injectingmaterial into a small opening in the mold. Element 107 may coincide withthe opening in the mold. In one embodiment, element 107 is used to helpposition light guide 100 into a housing. As noted, the light exit 112may be rectangular. Element 107 may be used to position the light exit122 properly.

As the term is used herein, a single piece light guide 100 is one inwhich the light rod 102 and lens 104 are both part of a single, unbrokenpiece of material. Note that a single piece light guide 100 differs fromone in which a lens is merely physically attached to the light rod 102(attached by optical grade epoxy, for example). As already mentioned,there are benefits to a single piece light guide 100 in terms ofease/cost of assembly, as well as accuracy of alignment.

Note that in some embodiments, light guide 100 is not a single pieceunit. For example, in one embodiment, lens 104 is manufactured as aseparate piece from the light rod 102. Lens 104 may be physicallyattached to light rod 102, or to one or more regions 106, 108 betweenthe light rod 102 and lens 104.

As noted, light guide 100 may have one or more regions (e.g., regions106, 108) between light rod 102 and lens 104. In general, a crosssection of these regions 106, 108 may be different in size and/or shapethan a cross section of light rod 102 and lens 104. The cross sectionbeing referred to here is orthogonal to the optical axis.

For example, region 106 may have a cross section that has a larger areathan the area of light exit 112 of light rod 102. Also, the shape ofregion 106 is not necessarily the same shape as light rod 102. In oneembodiment, region 106 has a cross section that is substantiallyrectangular (which may include a square). However, corners of region 106may be rounded or cut off.

Region 106 has a lower surface (FIG. 1, 116), one or more top surfaces(FIG. 2, 119), and one or more side surfaces (FIG. 2, 126). In theembodiment of FIG. 2 there are a total of four top surfaces 119, andeight side surfaces 126. There may be more or fewer than four topsurfaces 119. There may be more or fewer than eight side surfaces. Forexample, there might be only four side surfaces 126. One or more of theside surfaces 126 may be substantially planar.

Region 108 may have a size and/or shape that is significantly differentfrom light rod 102 and/or lens 104. In one embodiment, region 108 has across section shaped like a polygon. The cross section being referred tois perpendicular to the optical axis. For example, region 108 may haveeight sides. However, region 108 could have more or fewer than eightsides.

Region 108 has outer or side surfaces (FIG. 2, 136). In the embodimentof FIG. 2 region 108 has eight side surfaces 136. There may be more orfewer than eight side surfaces to region 108. In one embodiment, fourside surfaces of region 108 are aligned with four sides of region 106.However, four other side surfaces of region 108 may be recessed somewhatsuch that region 106 has ridges. Note that a top surface 119 may definethe extent of a ridge. The ridges may help to align light guide 100 intoa housing. The ridges may also help to secure light guide 100 in place.

As noted, light guide 100 is not required to have regions 106, 108between light rod 102 and lens 104. FIG. 5 depicts one embodiment of alight guide 100 without such regions. FIG. 5 shows a plan view in whichlens 104 is directly adjacent to light exit 112 of light rod 102. In oneembodiment, light guide 100 is a single piece having a light rod 102that is physically adjacent to a lens 104.

FIG. 6 depicts one embodiment of light guide 100 optically coupled to alight source module 604. The light source module 604 has one or moreLEDs on a PC board 619, or the like. In some embodiments, there is onered, one blue, and two green LEDs in a Bayer pattern. The light sourcemodule 604 may have a thermistor, for sensing temperature near the LEDs.

Light entrance 110 of light guide 100 is located to capture light fromthe light source 640. The size and shape of light entrance 110 of lightguide 100 may be designed to match the size and shape of light source640. For example, the surface of light entrance 110 could be flat. Thesurface of light entrance 110 could be concave, such that light source640 can fit at least partially into the concave opening.

Light entrance 110 may be placed in close proximity to light source 640to improve efficiency of light capture. In some embodiments, there is agap between light source 640 and light guide 100. With an air gap theremay be some air gap Fresnel loss, resulting in a loss of light capture.In one embodiment, the surface area of light entrance 110 is slightlylarger than the area of light source 640, which may limit Fresnel lossesacross the gap. The gap may be filled with a material that is designedto improve optical properties. In one embodiment, a flux focusing lensis placed between light source 640 and light entrance 110 to improvelight capture.

In some embodiments, light source 640 is physically attached to lightguide 100. For example, light source 640 may be glued to light entrance110 with optical grade epoxy. The flux capture may be essentially 100%in this case. However, note that physically attaching light source 640to light entrance 110 is not required.

Note that light source 640 is not required to be provided by LEDs. Asone alternative, light source 640 is provided by one or more lasers.

In one embodiment, pulse width modulation (PWM) is used to controlintensity and/or color output by the light source 640 (e.g., LEDs. Inone embodiment, each of the LEDs may be independently controlled by aPWM signal. The PWM signal may turn an LED on or off by controlling thecurrent to the LED. In one embodiment, the PWM signal includes a trainof pulses at a fixed frequency. The pulse width may be modulated tocontrol light intensity from an LED. The PWM signals may be undercontrol of a processor. Note that the light source 640 may be controlledby a control signal other than a PWM signal.

FIG. 7A depicts a block diagram of one embodiment of a light engine 700in which embodiments of light guide 100 may be used. Light engine 700may be used to project a light image, including both still and movingimages. Light engine 700 includes a light source module 604, light guide100, housing 800, relay lenses and mirror 712, polarization beamsplitter (PBS) 706, panel module 710, pre-polarizer 714, post polarizer717, and projection lens module 708. Note that some elements are notdepicted. For example, the light engine 700 could also have variousgears for adjusting the projection lenses 708.

Light source module 604 may include one or more LEDs, in one embodiment.In some embodiments, more than one color of LED is used. For example,one or more red, green, and blue LEDs may be used. In one embodiment,the LEDs have a Bayer pattern. The LEDs may reside on a circuit board.Note that instead of an LED module, a laser module (or other lightgeneration technology) could be used.

Any of the embodiments of light guide 100 described herein may be usedfor the light guide 100. Note that light guide 100 may be surrounded byhousing 800, which may help to properly align light guide 100 to lightsource module 604. Together, housing 800, light source module 604, andlight guide 100 may be referred to as a light source housing assembly.

Light guide 100 may integrate and collimate the LED light. Thiscollimated light may be transmitted to pre-polarizer 714 via the relaylenses and mirror 712. The relay lenses and mirror 712 could include afirst relay lens, a mirror, and a second relay lens.

Pre-polarizer 714 may linearly polarize the collimated light. Forexample, the pre-polarizer 714 may polarize the light to the Spolarization state (e.g., perpendicular to the incidence plane).Pre-polarizer 714 may work with the PBS 706 to enhance contrast, as willbe explained later. In some embodiments, pre-polarizer 714 polarizes thelight to the same polarization state that the PBS 706 passes to thepanel module 710.

The PBS 706 may include two prisms with their hypotenuse surfacesjoined. One prism receives light from pre-polarizer 714. The PBS 706 isable to transmit light of one polarization state (e.g., S-state) topanel module 710. Note that PBS 706 may, alternatively, transmit lightthat is P-polarized to panel module 710 (if the panel module 710 werelocated elsewhere). For example, panel module 710 could be located abovethe PBS 706 in FIG. 7A. Therefore, instead of reflecting S-state lightto panel module 710, the PBS 706 could allow P-state light to passstraight through both prisms to panel module 710. In this case,pre-polarizer 714 may polarize the light to the P-state.

Note that the PBS 706 may not be completely efficient at transmittinglight of one polarization and blocking light of another. In other words,its polarization selectivity may not be 100 percent. In order to producea projected image of high contrast, the PBS 706 should have a highselectivity between polarizations (e.g., between S-state and P-state).Pre-polarizer 714 may help to improve contrast by polarizing the lightprior to the PBS 706, which may improve the polarization selectivity ofthe PBS 706.

Panel module 710 includes a liquid crystal on silicon (LCoS) module, inone embodiment. An LCoS device may include a silicon substrate thatsupports liquid crystals. There may be a reflective surface below theliquid crystals. Liquid crystals may have the ability to alter thepolarization of light, based on their state. For example, in one statethe liquid crystals may align themselves such that the light is notaffected. For some devices this may be achieved by application of avoltage or current to the liquid crystals. However, in another state,the liquid crystals may alter the polarization. The state of the liquidcrystal molecules may be controlled by an active matrix array ofcomplementary metal-oxide-semiconductor (CMOS) transistors. Therefore,the liquid crystal molecules may be controlled at a pixel level. As oneexample, the transistors may selectively rotate axes of the liquidcrystal molecules.

Thus, panel module 710 may comprise pixels capable of changing thepolarization direction of light. For example, S-polarized light may bechanged to P-polarized light. Alternatively, if the PBS 706 transmitsP-polarized light to the panel module 710, then the panel module 710 maychange the light to S-polarized light. In either case, one polarization(e.g., S-state) may be referred to as the bright state, whereas theother polarization (e.g., the P-state) may be referred to as the darkstate. Therefore, an image may be formed by the combination of lightstate and dark state pixels.

Light that leaves panel module 710 travels back through the PBS 706 andto the post polarizer 717. Post polarizer 717 may help to improvecontrast. In some embodiments, the PBS 706 primarily transmits P-statelight towards projection lens module 708. S-state light that leavespanel module 710 may be reflected by the PBS 706 away frompost-polarizer 717. However, due to limited polarization efficiency, thePBS 706 may transmit some S-state light towards projection lens module708. Post-polarizer 717 may filter out the S-polarized light, therebyimproving contrast.

Projection lens module 708 may magnify the imaged light and project theimaged light to obtain a desired full color image. Projection lensmodule 708 may have several lenses, which may be controlled by gears orother mechanisms to help focus the image.

Note that light engine 700 was described as having an LCoS device in thepanel module 710. However, other technologies could be used in panelmodule 710. Another example is a digital micro mirror (DMD).

Also note that light engine 700 uses reflective technologies in oneembodiment of panel module 710. However, transmissive technologies canalso be used. In this case, the PBS 706 may not be required. An exampletransmissive technology is an LCD imager. FIG. 7B depicts a blockdiagram of one embodiment of a light engine' 750 that uses transmissivetechnology in panel module 710. Light engine' 750 may use variousembodiments of a light guide 100 disclosed herein. Light source module604 could include one or more different colored LEDs. Light guide 100may provide collimated light to polarizer 754. Polarizer 754 maypolarize the light in a first polarization state. For example, it maypolarize the light to the S-state. The other polarizer 757 may allowlight that is polarized in another orientation (e.g., P-state) to passto projection lens module 708. Thus, light guide 100 may be used toprovide collimated light for a transmissive device, such as an LCDimager.

FIG. 7C depicts further details of one embodiment of light engine 700 inwhich embodiments of light guide 100 may be used. FIG. 7C depictsfurther details of one embodiment of light engine 700 of FIG. 7A. Lightsource module 604 includes a light source 640 and PC board 619, in thisembodiment. The light source 640 includes four LEDs, in one embodiment.The light source 640 could include more or fewer LEDs. The light source640 could be a different type of light source, such as laser light. Therelay lenses and mirrors 712 include relay lens 733, mirror 737, andrelay lens 735, in this embodiment. The panel module 710 includes a LCoSelement 742 on a board 744, in this embodiment. The projection lensmodule 708 includes lenses 762, 764, 766, and 768, in this embodiment.The post polarizer 717 is also depicted as part of the projection lensmodule 708, although it could be considered to be outside of theprojection lens module 708.

As noted, there may be a housing 800 around light guide 100 in someembodiments. FIG. 8A depicts a perspective view of one embodiment of ahousing 800. FIG. 8B depicts a top plan view of one embodiment ofhousing 800. FIG. 8C depicts a cross sectional view of one embodiment ofhousing 800. The following discussion will refer collectively to FIGS.8A-8C. Housing 800 may have an opening 801 into which light rod 102 mayfit. FIG. 8A shows the top portion of the opening 801 is surrounded by aplatform 803. The platform 803 may support light guide 100. The opening801 has a conical shape in some embodiments. FIG. 8C shows a crosssection to depict the conical shape of one embodiment of the opening801. FIG. 8B shows the opening from a top plan view. Surface 823 is theinside surface of the opening 801. Edge 841 is the edge between theopening 801 and the platform 803 of the housing. Edge 842 is the edge atthe bottom of the conical opening 801.

The shape of the opening 801 may be designed based on the shape of lightrod 102. For example, referring back to FIG. 2, light rod 102 may betapered. One embodiment of a tapered light rod embodiment may thus beinserted into one embodiment of conical opening 801. Moreover, a taperedlight rod may be physically supported by the housing 800. This will bediscussed in more detail below.

As noted, housing 800 may have a platform 803 for supporting, orotherwise contacting, lower surface 116 of region 106 of light guide100. Referring to FIG. 8A, housing 800 may have surfaces 805 forsupporting, or otherwise contacting, side surfaces 136 of region 108 oflight guide 100. Note that it is not required that surfaces 805 maintainphysical contact with the light guide 100.

Housing 800 may have alignment pins 821, which can be used to align thehousing 800 into a light engine (e.g., 700, 750), or other opticaldevice. For example, the light engine may have holes that acceptalignment pins 821. Therefore, light guide 100 may be precisely alignedto optical elements in a light engine. Moreover, light guide 100 may besecured in place in the light engine, such that it is not misaligned doto shocks, vibrations, etc.

Note that housing 800 may help to properly align the light guide 100 tolight source 640 (e.g., LEDs). Referring to FIG. 8C, light source 640can be seen at the bottom of opening 801. Light source 640 may sit on aPC board (or the like) 619 on light source module 604. The housing 800may be adapted to fit precisely to a light source module 604 tofacilitate alignment. As noted, light sources other than LED may beused.

FIG. 8D depicts a side plan view of one embodiment of housing 800 withlight guide 100 inside. Housing 800 has an exterior piece 820 and aninterior piece 810, in this embodiment. Briefly, interior piece 810 mayhave opening 801 that supports light rod 102. Exterior piece 820 mayhelp to secure light guide 100 into housing 800. These two pieces(interior piece) 810, (exterior piece) 820 will be discussed in moredetail below. As can be seen in FIG. 8D, region 108 and lens 104 oflight guide 100 extend above housing 800. Housing 800 is depicted asattached to light source module 604. Together, the housing 800, lightguide 100, and light source module 604 may be referred to as a lightsource housing assembly 900.

FIG. 8E depicts an interior piece 810 of housing 800 surrounding lightguide 100. Region 106 of light guide 100 has its lower surface 116(lower surface 116 not depicted in FIG. 8E) in contact with platform 803of interior piece 810 (platform 803 not depicted in FIG. 8E). Referringback to FIG. 1, lower surface 116 of region 106 may be seen. Referringback to FIGS. 8A and 8B, lower surface 116 may rest on platform 803.

FIG. 8F depicts a perspective view of one embodiment of a two-piecehousing 800. FIG. 8F shows both interior piece 810 and exterior piece820. The interior piece 810 may be the same as the one depicted in FIG.8E. As will be discussed below, the exterior piece 820 may help tosecure light guide 100 in housing 800.

FIGS. 9A-9C depict one embodiment of interior piece 810 of housing 800.This may be similar to the interior piece 810 depicted in FIG. 8E. Asnoted, interior piece 810 may have an opening 801 that surrounds andsupports one embodiment of light guide 100. FIG. 9A depicts a side planview. FIG. 9B depicts a cross section at line B-B of FIG. 9A. FIG. 9Cdepicts a cross section at line C-C of FIG. 9A.

Referring to FIGS. 9B and 9C, a cross section of light rod 102 may beseen in opening 801. Because light rod 102 tapers in one embodiment, ithas a larger cross section in FIG. 9C than 9B. Interior piece 810 mayphysically contact light rod 102. In one embodiment, interior piece 810physically contacts edges of light rod 102, but does not physicallycontact sides of light rod 102. Interior piece 810 may physicallycontact light rod 102 from substantially light entrance 110 to lightexit 112. However, note that is it not required that physical contact bemaintained all of the way from light entrance 110 to light exit 112. Forexample, referring to FIG. 9A, a portion of light rod 102 near lightentrance 110 might not be in physical contact with interior piece 810.

Further note that interior piece 810 may itself include an inner portion813 and an outer portion 817. Inner portion 813 may be conical in shapeand may support light rod 102. Outer portion 817 may surround innerportion 813. Referring to FIG. 9B, these two portions 813, 817 may bephysically joined by four small segments. More or fewer segments couldbe used. Referring to FIG. 9C, inner portion 813 may be larger near thetop such that part of it may merge with outer portion 817. In oneembodiment, inner portion 813 is black, which may absorb stray lightfrom light rod 102.

Note that interior piece 810 of housing 800 may physically support lightrod 102 during use. One benefit of this is that housing 800 may preventlight rod 102 from deforming, bending, mis-aligning, etc. during use.Note that light guide 100 may be used in a device that is very small.Also note that the device could be mobile. For example, light guide 100might be used in a projector (or other optical device) in a cellulartelephone or other portable electronic device. It is possible that thedevice could be dropped. Housing 800 may keep light rod 102 properlyaligned in such an event.

For some devices (e.g., cellular telephones) and some safetyregulations, the resonant frequency should be more than 2 kHz. Someembodiments of the light guide 100 could be used inside such devices. Byphysically supporting the light rod 102, housing 800 may preventdeformations of light rod 102 during use. The light rod 102 and/orhousing 800 of some embodiments may also contribute to a wide range ofresonant frequencies greater than 2 kHz.

FIG. 10 depicts a cross section of one embodiment of housing 800 andlight guide 100. In this embodiment, housing 800 includes two pieces.FIG. 10 shows the same view as FIG. 8D. FIG. 10 depicts interior section810 surrounding the light rod 102. Note that from this view, interiorsection 810 does not make physical contact with light rod 102 along thesidewalls of light rod 102. Referring back to FIGS. 9B and 9C this canbe understood by noting that interior section 810 might only physicallycontact the light rod 102 at the four edges of the light rod 102. Notethat the cross section in FIG. 10 does not show the edges of the lightrod 102.

As noted herein, interior section 810 may itself include two joinedpieces. FIG. 10 shows an inner portion 813 in the middle, which may bejoined to a flat exterior portion 817. Having the inner portion 813 inthe middle may provide for some amount of flexibility when light rod 102is inserted. For example, when light rod 102 is inserted in opening 801,the inner portion 813 may expand somewhat. This may allow for goodphysical contact while relaxing tolerances of part sizes. However, insome embodiments, the interior section 810 does not have to portions 813and 817. Instead, interior section may include a single portion.

Note that in FIG. 10, lower surface 116 of the region 106 is on platform803 of interior section 810. Further note that exterior piece 820 ofhousing 800 secures light guide 100. Exterior piece 820 may be inphysical contact with one or more top surfaces 119 of region 106.Exterior piece 820 may be in physical contact with the one or more sidesurfaces 136 of region 108.

As noted, housing 800 includes two separate pieces, in this embodiment.This may allow easy assembly of housing 800 around light guide 100. Forexample, first the light guide 100 may be placed into opening 801 ofinterior section 810 (without exterior piece 820 in place). Then,exterior piece 820 can be configured into place over top surface 119 ofregion 106 and adjacent to one or more side surfaces 136 of region 108to secure light guide 100 into place.

Note that when the light guide 100 is in the housing 800 that one ormore sidewalls of the light guide 100 may be in physical contact withhousing 800. For example, some portion of side surfaces 136 of region108 may contact the housing 800. It is also possible for lower surface116 of region 106 to contact housing 800. Some portion of side surfaces116 of region 106 may also contact housing 800. Even though someembodiments of light guide 100 operate by total internal reflection,there is little or no light lost as a result of this contact. This isbecause the sidewalls that may contact the housing 800 may be away fromthe optical path between the light exit 112 and lens 104.

FIG. 11 depicts a cross section of one embodiment of housing 800 andlight guide 100. In this embodiment, housing 800 includes a singlepiece. The lower surface 116 of region 106 physically contacts a surface1103 of the housing 800. Surface 1103 may be similar to platform 803 ofone embodiment in which housing has two pieces. Surface 1103 cannot beseen in FIG. 11, but the edge of surface 1103 is pointed to.

Side surfaces 126 (not depicted in FIG.11) of region 106 may physicallycontact housing 800, in the embodiment of FIG. 11. Therefore, lightguide 100 can easily and accurately be placed into housing 800, suchthat light rod 102 is in the opening 801. Housing 800 of a one pieceembodiment will therefore physically support light rod 102. Note thatopening 801 of embodiments of a one piece housing may have a conicalopening, which may support a tapered light rod.

One or more elements 1104 may be used to help secure light guide 100into the housing 800. Element(s) 1104 may be affixed to housing 800 tohold the light guide 100 into the housing. For example, element 1104 maybe physically attached to a sidewall of housing 800. Optionally, element1104 could be affixed to a portion of the light guide 100, but this isnot required. In some embodiments, element 1104 is in physical contactwith one or more surfaces of light guide 100 to secure light guide 100into place. Element 1104 may be in physical contact with top surface 119(not depicted in FIG. 11) of region 106 and/or side surfaces 136 (notdepicted in FIG. 11) of region 108.

Also note that housing 800 of a one piece embodiment may be attached tolight source module 604. Therefore, light rod 102 may be preciselyaligned to light source 640.

FIG. 12 depicts a flowchart of one embodiment of a process 1200 ofmanufacturing a single piece light guide 100. The process 1200 may beused to form various embodiments of single piece light guides 100disclosed herein.

Step 1202 includes forming a single piece light guide that has a lightrod 102 and lens 104. The light guide 100 may optionally have one ormore of regions (e.g., regions 106 and/or 108) between the light rod 102and lens 104.

In some embodiments, the single piece light guide 100 is formed using aninjection molding process. This may include using a mold that isconfigured to form a single piece light guide. Light guide 100 may beformed from an optical grade material. Examples of optical gradematerials include, but are not limited to, acrylic resins,polycarbonates, epoxies, and glass. In some embodiments, the entirelight guide 100 is formed from the same material. However, in someembodiments, light guide 100 is formed from two or more differentmaterials. In one embodiment, light rod 102 is solid. For example, lightrod 102 may be a solid integrating optic. In one embodiment, light rod102 is hollow.

FIG. 13 depicts a flowchart of one embodiment of a process 1300 ofconfiguring a light source housing assembly 900 into a light engine.Process 1300 may be used to assemble various embodiments of light sourcehousing assemblies 900 disclosed herein. Process 1300 may be used witheither a one piece housing or a two piece housing.

In step 1302, light rod 102 of light guide 100 is placed into opening801 of housing 800. The opening 801 may be conical, and the light rod102 may be tapered. Edges of the light rod 102 may physically contactthe housing 800, as depicted in FIGS. 9B, 9C, such that the conicalportion supports light rod 102. In one embodiment, element 107 is usedto properly align the light rod 102 into the housing 800, such thatlight exit 112 is properly positioned. For example, the light exit 112may have a rectangular shape. Element 107 may be used to properly orientthe rectangular shape such that light is projected with the desiredaspect ratio.

Also, a lower surface 116 of the region 106 may physically contact oneor more platforms or surfaces 803 of housing 800. FIG. 10 depicts across-section showing how the lower surface 116 of the region 106 maycontact the housing (note that as of step 1302 the exterior piece 820will not yet be in place). FIG. 11 depicts another example of how thelower surface 116 of the region 106 may contact the housing. However,note that element 1104 is not yet in place, as of step 1302. FIGS. 13Aand 13B provide further details of embodiments of step 1302.

In step 1304, housing 800 is configuring around light guide 100. Step1304 may result in light guide 100 being held or secured in housing 800.In one embodiment, light guide 100 has a ridge between light rod 102 andlens 104. In step 1304, the housing may be configured around the ridge.FIGS. 13A and 13B provide further details of embodiments of step 1304.

In step 1306, housing 800 is attached to light source module 604. FIG.8D depicts housing assembly 900 attached to light source module 604.Note that instead of an LED module, a different type of light sourcecould be used.

In step 1308, light source housing assembly 900 is placed into a lightengine (e.g., 700, 750). In some embodiments, housing 800 has alignmentpins 821 to assist. The light engine may have a casing with small holeslocated strategically to accept the alignment pins 821.

FIG. 13A depicts a flowchart of one embodiment of a process 1320 ofconfiguring a light source housing assembly 900. Process 1320 may beused to implement steps 1302-1304 of process 1300. Process 1320 may beused with one embodiment of a two piece housing 800.

In step 1322, light rod 102 may be placed into opening 801 in interiorpiece 810 of housing 800. In step 1322, lower surface 116 of region 106may be placed onto platform 803. Step 1322 is one embodiment of step1302.

In step 1324, exterior piece 820 of housing 800 is configured aroundlight guide 100. In one embodiment, after exterior piece 820 is placedaround interior piece 810, the two pieces are mated together. Forexample, the two pieces may be designed to “snap” together such thatexterior piece 820 stays in place. Alternatively, an adhesive (e.g.,epoxy) may be used to hold exterior piece 820 to interior piece 810.Step 1324 may result in the light guide 100 being held securely in thehousing 800. FIG. 10 depicts one embodiment in which the exterior piece820 is in place around the light guide 100. Step 1324 is one embodimentof step 1304.

FIG. 13B depicts a flowchart of one embodiment of a process 1340 ofconfiguring a light source housing assembly 900. Process 1340 may beused to implement steps 1302-1304 of process 1300. Process 1340 may beused with one embodiment of a one piece housing 800.

In step 1342, light rod 102 is placed into opening 801 in housing 800.Step 1342 is one embodiment of step 1302. Referring to FIG. 11, lightrod 102 may be placed into the opening 801 such that lower surface 116of region 106 contacts surface 1103 of housing 800. Note that elements1104 are not yet in place.

In step 1344, an element 1104 is affixed in place to secure the lightguide 100 into housing 800. Referring to FIG. 11, one or more elements1104 may be affixed to the housing 800 to hold the light guide 100 intothe housing. For example, element 1104 may be physically attached to asidewall of housing 800. Optionally, element 1104 could be affixed to aportion of light guide 100, but this is not required. In someembodiments, element 1104 is in physical contact with one or moresurfaces of light guide 100 to secure light guide 100 into place.Element 1104 may be in physical contact with top surface 119 of region106 and/or side surfaces 136 of region 108. Step 1344 is one embodimentof step 1304.

One embodiment disclosed herein includes a single piece light guide. Thesingle piece light guide may include a light rod and a lens. The lightrod has a first end, a second end, and may have at least one sidebetween the first and second ends. The first end is for receiving light,and the second end serves as a light exit. The lens is optically coupledto the light exit. The light rod may be an integrating optic, and may besolid. The single piece light guide may also have one or more regionsbetween the light rod and the lens. The one or more regions have anouter surface that extends beyond the light exit. At least a portion ofthe outer surface of the region may be substantially planar.

One embodiment includes a method for fabricating a single piece lightguide. The method may include forming a single piece having a light rodand a lens. The light rod has a first end and a second end. The firstend is for receiving light; the second end has a light exit. The lens isoptically coupled to the light exit of the light rod. The single piecelight source may be formed using an injection molding process. Thesingle piece light source may also include a region between the lightrod and the lens. The region has an outer surface that may extend beyondthe light exit. At least a portion of the outer surface of the regionmay be substantially planar.

One embodiment includes a light engine, which may comprise a lightsource and a single piece light guide. The single piece light guide mayhave a light rod and a lens. The light rod may have a first end, asecond end, and at least one side between the first and second ends. Thefirst end receives light from the light source; and the second end has alight exit. The lens is optically coupled to the light exit of the lightrod. The light engine may further include a housing around the lightguide. The housing may physically contact at least a portion of thelight rod from substantially the first end to the second end of thelight rod.

One embodiment includes a single piece light guide comprising firstmeans for capturing and transmitting light from a light source, andsecond means for collimating light from the first means. The first andsecond means are formed as one piece.

One embodiment includes an assembly comprising a light guide and ahousing. The light guide has a light rod having a first end forreceiving light, and a second end having a light exit. The light rodtapers from the second end to the first end. The light guide also has alens that is optically coupled to the light exit of the light rod. Theassembly also has a housing having a conical portion that supports thelight rod. The light guide may include a first region and a secondregion between the light rod and the lens. The first region may includea ridge that extends beyond the second region and the light exit. Thehousing may be configured to hold the light guide in place by securingthe ridge.

One embodiment includes a method for assembling a light source housingassembly. The method comprising accessing a light guide that includes alight rod and a lens. The light rod having a first end and a second end,with the first end for receiving light. The light rod has a light exitat the second end. The light rod tapers from the second end to the firstend. The light rod has a lens that is optically coupled to the lightexit of the light rod. The method includes placing the light guide intoa housing having a conical portion such that the conical portionsupports the light rod. The method may further include configuring thehousing around a ridge of the light guide.

One embodiment includes a light engine comprising a light source, alight guide and a housing. The light guide has a light rod having afirst end and a second end. The first end receives light from the lightsource. The light rod has a light exit at the second end. The light rodtapers from the second end to the first end. The light rod has a lensthat is optically coupled to the light exit of the light rod. Thehousing had a conical interior that supports the light rod.

One embodiment includes a light guide that includes a light rod, a lens,and one or more regions between the light rod and the lens. The lightrod has a first end and a second end. The first end is for receivinglight. The light rod has a light exit at the second end. The lens isoptically coupled to the light exit of the light rod. The one or moreregions has at least one outer surface that extends beyond the lightexit. In one embodiment, a cross section of at least a portion of theone or more regions in a first direction perpendicular to the first endto the second end of the light rod is shaped differently than a crosssection of the lens in the first direction. In one embodiment, a portionof the outer surface is substantially planar. In one embodiment, thelight rod is an integrating optic.

One embodiment includes a method for fabricating a light guide. Themethod may comprise forming a light rod, forming a lens, and forming aregion between the light rod and the lens. The light rod may have afirst end and a second end. The first end may be for receiving light.The light rod has a light exit at the second end. The lens is opticallycoupled to the light exit of the light rod. The region has an outersurface that extends beyond the light exit. In one embodiment, injectionmolding is used to form the light guide having the light rod, the lens,and the region.

One embodiment includes a light engine comprising a light source and alight guide. The light guide has an integrating optic, a lens, and oneor more regions between the integrating optic and the lens. Theintegrating optic has a first end and a second end. The first endreceives light from the light source. The integrating optic has a lightexit at the second end. The lens is optically coupled to the light exitof the integrating optic. The one or more regions have at least oneouter surface that extends beyond the light exit. In one embodiment, thelight engine includes a panel module for creating an image, wherein thelight guide provides light to the panel module to be used to create theimage.

The foregoing detailed description of embodiments has been presented forpurposes of illustration and description. It is not intended to beexhaustive or to limit embodiments to the precise form disclosed. Manymodifications and variations are possible in light of the aboveteaching. The described embodiments were chosen in order to best explainthe principles and practical applications, to thereby enable othersskilled in the art to best utilize the various embodiments and withvarious modifications as are suited to the particular use contemplated.It is intended that the scope be defined by the claims appended hereto.

What is claimed is:
 1. A single piece light guide, comprising: a lightrod; and a lens formed as one piece with the light rod, the light rodhaving a first end and a second end, the first end for receiving light,the second end serves as a light exit, the lens is optically coupled tothe light exit, the light rod and the lens are formed from a singlepiece of the same material.
 2. The light guide of claim 1, wherein: thelight rod is a solid integrating optic.
 3. The light guide of claim 1,wherein: the light rod tapers from the second end to the first end. 4.The light guide of claim 1, wherein: the lens is a convex lens.
 5. Thelight guide of claim 1, wherein: the lens is a collimating lens.
 6. Asingle piece light guide, comprising: a light rod; and a lens formed asone piece with the light rod, the light rod having a first end and asecond end, the first end for receiving light, the second end serves asa light exit, the lens is optically coupled to the exit; and one or moreregions between the light rod and the lens, the one or more regions hasat least one outer surfaces, the at least one outer surfaces extendsbeyond the light exit, at least a portion of the at least one outersurfaces is substantially planar.
 7. The light guide of claim 6,wherein: the one or more one or more regions includes a first region anda second region, the first region includes a ridge that extends beyondthe second region and the light exit.
 8. A method for fabricating alight guide, comprising: forming a single piece having a light rod and alens, the light rod having a first end and a second end, the first endfor receiving light, the second end has a light exit, the lens isoptically coupled to the light exit of the light rod, the forming asingle piece includes forming the light rod and the lens using the sameinjection molding process, the forming the single piece includes usingthe same material to form the light rod and the lens.
 9. A methodfabricating a light guide, comprising: forming a single piece having alight rod and a lens, the light rod having a first end and a second end,the first end for receiving light, the second end has a light exit, thelens is optically coupled to the light exit of the light rod, whereinthe forming the light guide includes: forming a region between the lightrod and the lens, the region has an outer surface, the outer surface ofthe region extends beyond the light exit, at least a portion of theouter surface of the region is substantially planar.
 10. The method ofclaim 9, wherein the forming the region includes: forming a ridge thatextends beyond the second end and the light exit.
 11. A light engine,comprising: a light source; a single piece light guide having a lightrod and a lens, the light rod having a first end, a second end, and atleast one surface between the first and second ends, the first endreceives light from the light source, the second end has a light exit,the lens is optically coupled to the light exit of the light rod; and ahousing around the light guide. the housing physically contacts at leasta portion of the light rod from substantially the first end to thesecond end of the light rod, but does not contact, the at least onesurface.
 12. The light engine of claim 11, wherein the light rod tapersfrom the second end to the first end, the housing has a conical portionthat supports the light rod.
 13. The light engine of claim 11, wherein:the light rod has a plurality of sides connected by a plurality ofedges, the sides and edges extend from the first end to the second endof the light rod, the housing physically contacts at least two of theedges but does not physically contact the sides.
 14. The light engine ofclaim 11, wherein: the light source includes a plurality of lightsources that emit a plurality of colors, the light rod integrates theplurality of colors.
 15. A light engine, comprising: a light source; anda single piece light guide having a light rod and a lens, the light rodhaving a first end, a second end, and at least one surface between thefirst and second ends, the first end receives light from the lightsource, the second end has a light exit, the lens is optically coupledto the light exit of the light rod, wherein the single-piece light guideincludes: a region between the light rod and the lens, the region has anouter surface, the outer surface of the region extends beyond the lightexit, at least a portion of the outer surface of the region issubstantially planar.
 16. The light engine of claim 15, wherein theregion has a ridge.
 17. The light engine of claim 16, furthercomprising: a housing around the light guide, the housing physicallycontacts at least a portion of the light rod from substantially thefirst end to the second end of the light rod, the ridge fits into thehousing.
 18. A single piece light guide, comprising: first means forreceiving and transmitting light from a light source; and second meansfor collimating light from the first means, the first and second meansformed as a single unbroken piece of the same material, the second meansoptically coupled to the first means.
 19. The single piece light guideof claim 18, wherein: the first means is for integrating the light fromthe light source.